Spring hanger system and methods of making and using same

ABSTRACT

An axle hanger includes a web, a first flange extending in a first direction perpendicular to the web, and a second flange extending in the first direction perpendicular to the web, spaced from and parallel to the first flange. A first return extends from the first flange toward the second flange parallel to the web, and a second return extends from the second flange toward the first flange parallel to the web. The axle hanger is easier to install and access in the event a hanger spring needs replacement, and the hanger can be more stably secured to the axle.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 62/686,345, filed Jun. 18, 2018, the entire content ofwhich is herein incorporated by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

(NOT APPLICABLE)

BACKGROUND AND SUMMARY

FIG. 1 shows a trailer axle 12 connected to a trailer frame 14 in aconventional manner. More specifically, FIG. 1 shows the trailer frame14 bearing first and second spring hanger brackets 16. The brackets 16may be made by bending a piece of steel sheet or plate into a U-shapealong first and second bend lines 18, 20 to define a web 22 and firstand second spaced apart and parallel flanges 24, 26. Each bracket 16 maybe attached to the frame 14 by butting the web 22 against a portion ofthe frame and welding the bracket to the frame along the first andsecond bend lines 18, 20 and along the opposed edges of the web 22extending between the first and second bend lines. The first flange 24defines a first flange aperture 28 proximate the free end thereof,opposite the web 22. Similarly, the second flange 26 defines a secondflange aperture 30 proximate the free end thereof, opposite the web 22.The first and second flange apertures 28, 30 are coaxially aligned alongan axis perpendicular to the first and second flanges 24, 26.

FIG. 1 also shows a U-bolt 31 and bracket 29 connecting the axle 12 tothe midpoint of a leaf spring 33. The ends of the leaf spring 33 defineapertures 32. Each aperture 32 is coaxially aligned with the first andsecond flange apertures 28, 30 of a corresponding bracket 16. A hangerbolt 34 extends through each of the first and second flange apertures28, 30 and the corresponding leaf spring aperture 32. The shank of thehanger bolt 34 typically includes a knurled portion near the head. Theknurled portion is configured to engage with a corresponding one of thefirst and second flanges 24, 26 to preclude rotation of the hanger boltwith respect to the corresponding one of the flanges 24, 26. In anembodiment, as shown in FIG. 1, one or more intervening components, forexample, equalizers, spring shackles, and the like, may be disposedbetween an end of the spring 33 and the corresponding bracket 16, andone of such intervening components may be connected to the spring 33 andthe corresponding hanger 16 in a similar manner.

The foregoing manner of connecting a trailer axle to a trailer frame hasnumerous drawbacks. For example, the brackets 16 have high residualstresses along the first and second bend lines 18, 20. Welding thebrackets 16 to the frame 14 along the bend lines 18, 20 can furtherincrease the stresses along the bend lines, ultimately leading tofractures of the brackets along the weld lines. Also, conventionaltechniques for installing the hanger bolts 34 involve pounding the boltsinto the brackets 16 with a sledge hammer to seat the knurled portion ofthe bolt's shank with the corresponding flange adjacent thecorresponding aperture. This technique can be dangerous and tiring, andit has the potential for damaging the bolts 34, the frame 14, thesprings 33, and the brackets 16. Further, once the hanger bolts 34 havebeen installed, they are difficult to remove, as might be necessary toreplace a broken spring 33.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other aspects and advantages will be described in detail withreference to the accompanying drawings, in which:

FIG. 1 is a perspective view of a trailer axle connected to a trailer ina conventional manner;

FIG. 2 is a perspective view of an illustrative spring hanger systemaccording to the present disclosure;

FIG. 3 is a perspective view of an illustrative spring hanger boltaccording to the present disclosure;

FIG. 4 is a perspective view of an illustrative spring hanger accordingto the present disclosure;

FIG. 5A is a top plan view of an illustrative blank from which thespring hanger of FIG. 4 may be formed;

FIG. 5B is an end elevation view of the blank of FIG. 5A formed to yieldthe spring hanger of FIG. 4;

FIGS. 6A-6C are front, side, and perspective views of anotherillustrative spring hanger system according to the present disclosure;

FIGS. 7A-7C are front, side, and perspective views of a furtherillustrative spring hanger system according to the present disclosure;

FIGS. 8A-8C are front, side, and perspective views of yet anotherillustrative spring hanger system according to the present disclosure;

FIGS. 9A-9C are front, side, and perspective views of yet a furtherillustrative spring hanger system according to the present disclosure;

FIGS. 10A-10C are front, side, and perspective views of still anotherillustrative spring hanger system according to the present disclosure;

FIGS. 11A-11H are various views of alternative spring hangers accordingto the present disclosure; and

FIGS. 12A-12E are various views of an alternative spring hanger boltaccording to the present disclosure.

DETAILED DESCRIPTION

FIGS. 2-4 show an illustrative axle bolt and hanger system 110 accordingto the present disclosure. The system 110 includes a hanger bolt 112(best shown in FIG. 3) and an axle hanger 114 (best shown in FIG. 4).The axle hanger 114 is configured to receive the axle bolt 112 and forconnection to a vehicle chassis frame, as will be discussed furtherbelow.

As shown, the bolt 112 includes a head 116, a locking tab 117 and ashank 118. The head 116 is generally planar, having a first surface andan opposed second surface. Also, the head 116 is generally rectangular,having a first dimension (or length) L and a second dimension (or width)W. In some embodiments, the length L is greater than the width W. Assuch, the head 116 defines two spaced apart and parallel relatively longedges and two spaced apart and parallel relatively short edges. Thelocking tab 117 extends generally perpendicularly from one of therelatively short edges of the head 116.

The shank 118 includes a first generally cylindrical portion 118A havinga first diameter and a second generally cylindrical portion 118B havinga second diameter lesser than the first diameter. The first cylindricalportion 118A extends perpendicularly from the first surface of the head116, in the same direction as the locking tab 117. The second generallycylindrical portion 118B extends coaxially from the first cylindricalportion 118A. The second cylindrical portion 118B may define an externalthread configured to receive a nut in threaded engagement, as will bediscussed further below.

The hanger 114 includes a discontinuous annular wall having a generallyrectangular cross section defining an interior region 115. Morespecifically, the hanger 114 includes a web 120, a first flange 122extending in a first direction perpendicular to the web, a second flange124 extending in the first direction perpendicular to the web, spacedfrom and parallel to the first flange, a first return 126 extending fromthe first flange toward the second flange parallel to the web, and asecond return 128 extending from the second flange toward the firstflange parallel to the web. Each of the first flange 122 and the secondflange 124 defines a corresponding aperture 130, 132 extending through alower portion thereof. The first aperture 130 and the second aperture132 are coaxial with each other and are each configured to receive thefirst cylindrical portion 118A of the shank 118 of the bolt 112 in snugand sliding engagement, as will be discussed further below.

As shown, the web 120 has a first length (LW), each of the first andsecond flanges 122, 124 has a second length (LF), and each of the firstand second returns 126, 128 has a third length (LR). The third length isslightly less than half of the first length. As such, the first andsecond returns 126, 128 cooperate to define a gap 134 between the freeends thereof. In an embodiment, the third length could be about half ofthe first length so that the free ends of the first and second returns126, 128 may abut each other. As shown, the second length is greaterthan the first length. In other embodiments, the second length could bethe same as or less than the first length.

In further embodiments, the first flange 122 could be longer or shorterthan the second flange 124. Also, the first return 126 could be longeror shorter than the second return 128.

With continued reference to FIG. 4, the web 120 has a first depth (topto bottom in FIG. 4), and the first and second flanges 122, 124 have asecond depth larger than the first depth as shown. In some embodiments,the first and second returns 126, 128 have a third depth or a returndepth that matches the first depth. The first and third depths extend toabout a midpoint M of the hanger 114. The apertures 130, 132 are shownpositioned beyond (i.e., below in FIG. 4) the first depth (i.e., belowthe midpoint M).

As best shown in FIGS. 5A and 5B, the hanger 114 may be formed from ablank 114′ made of (i.e., cut or stamped from) metal sheet or plate. Theblank 114′ may be cut to form a first web portion 120′, a first flangeportion 122′ immediately adjacent the web portion along a first bendline or region 121′, a second flange portion 124′ immediately adjacentthe web portion along a second bend line or region 123′ spaced from andparallel to the first bend line, a first return portion 126′ immediatelyadjacent the first flange portion along a third bend line or region 125′spaced from and parallel to the first bend line, and a second returnportion 128′ immediately adjacent the second flange portion along afourth bend line or region 127′ spaced from and parallel to the secondbend line. The first and second flange portions 122′, 124′ may bedrilled, punched or otherwise formed to define the first and secondapertures 130, 132, respectively.

With reference to FIGS. 5A and 5B, the first flange portion 122′ may bebent with respect to the web portion 120′ along the first bend line 121′so that the first flange portion and the web portion are generallyperpendicular to each other. The second flange portion 124′ may be bentwith respect to the web portion 120′ along the second bend line 123′ sothat the second flange portion and the web portion are generallyperpendicular to each other and so that the first flange portion 122′and the second flange portion 124′ are opposite and generally parallelto each other. The first return portion 126′ may be bent with respect tothe first flange portion 122′ along the third bend line 125′ so that thefirst return portion and the first flange portion are generallyperpendicular to each other and so the that first return portion extendsfrom the first flange portion toward the second flange portion 124′ andthe second return portion 128′. The second return portion 128′ may bebent with respect to the second flange portion 124′ along the fourthbend line 127′ so that the second return portion and the second flangeportion are generally perpendicular to each other and so that the secondreturn portion extends from the second flange portion toward the firstflange portion 122′ and the first return portion 126′.

With the hanger 114 so formed, the first and second returns 126, 128 maybe, but need not be, generally coplanar with each other, and the freeends thereof may be, but need not be, proximate or in abutment with eachother.

The forgoing bend sequence to form the hanger 114 from the blank 114′ isillustrative. In practice, any desired bend sequence may be adopted.

Respective first (or upper) ends of the web 120, the first flange 122,the second flange 124, the first return 126, and the second return 128(that is, the end opposite the first and second apertures 130, 132)cooperate to define an edge 136 configured to abut a structural memberto which the hanger 114 may be attached. For example, the edge 136 ofthe hanger 114 may be abutted against a chassis frame and any or all ofthe web 120, the first flange 122, the second flange 124, the firstreturn 126, and the second return 128 of the hanger may be welded to thechassis frame at or proximate the edge 136. The weld may be continuousor stitched. The weld may be made around the outer perimeter of thehanger 114, the inner perimeter of the hanger, or both.

An end of a leaf spring or spring shackle having a mounting aperture maybe received within the interior region 115 defined by the hanger 114,with the spring or shackle mounting aperture coaxial with the first andsecond apertures 130, 132, respectively, of the first and second flanges122, 124. The bolt 112 may be inserted through the first aperture 130,through the mounting aperture of the spring or shackle, and through thesecond aperture 132, so that corresponding parts of the first portion118A of the shank 118 are received within the first and second apertures130, 132, so that the second portion 118B of the shank extends outwardlyfrom the outer surface of the second flange 124, and so that the lockingtab 117 engages with the free (or lower) end of the first flange 122. Anut (not shown) may be threaded onto the threaded portion of the secondportion 118B of the shank 118, thereby retaining the bolt 112 and thespring or shackle to the hanger 114. A suitable locking device, forexample, a lock washer, could be disposed between the nut and the secondflange. In an embodiment, the bolt 112 could be inserted through thesecond aperture 132, the mounting aperture of the spring or shackle, andthe first aperture 130 in an orientation opposite to that describedabove.

One skilled in the art would recognize that the locking tab 117 of thebolt 112 is configured to engage with the corresponding one of the firstand second flanges 122, 124 to preclude rotation of the bolt when thenut is tightened thereto. This anti-rotation feature may allow anassembler to assemble a spring or shackle to the hanger 114 using fewertools than when assembling a spring or shackle to a conventional springhanger, and with less effort.

FIGS. 6A-6C show another illustrative system 210 including a bolt 212and a hanger 214 according to the present disclosure. The system 210 isin many or most respects similar to the system 110 and will be discussedherein primarily in terms of its differences from system 110. Featuresof the system 210 having counterparts in the system 110 may be referredto herein using like terms and may be identified by like referencecharacters, incremented by 100.

The bolt 212 differs from the bolt 112 primarily in that the head 216 ofthe bolt 212 is a generally conventional hex head that further includesa bendable locking tab 217 extending from opposing flats of the hexhead, proximate the interface between the head 216 and the shank 218.The bolt 212 otherwise is similar to the bolt 112. As shown, the system210 includes a conventional U-shaped hanger 214 having first and secondflanges 222, 224, although a hanger similar to the hanger 114 iscontemplated for use in the system 210.

With the bolt 212 inserted through the first and second flanges 222, 224(and the spring or spring shackle mounting aperture), the locking tab217 may be bent against the free end of the corresponding one of thefirst flange and the second flange (as shown by the arrow in FIGS. 6Aand 6C) to preclude rotation of the bolt with respect to the hanger 214.

FIGS. 7A-7C show a further illustrative system 310 including a bolt 312and a hanger 314 according to the present disclosure. The system 310 isin many or most respects similar to the system 110 and will be discussedherein primarily in terms of its differences from system 110.

Features of the system 310 having counterparts in the system 110 may bereferred to herein using like terms and may be identified by likereference characters, incremented by 200.

The bolt 312 differs from the bolt 112 primarily in that the head 316 ofthe bolt 312 is a conventional hex head. The bolt 312 otherwise issimilar to the bolt 112. As shown, the system 310 includes aconventional U-shaped hanger 314 having first and second flanges 322,324, although a hanger similar to the hanger 114 is contemplated for usein the system 310.

Unlike the system 110, the system 310 also includes an S-shaped washer313 having a base 313A, a first locking tab 313B extending in a firstdirection from the base, and a second locking tab 313C extending fromthe base in a second direction, the second direction opposite the firstdirection. The washer 313 is disposed between the head 316 of the bolt312 and the outer surface of the first flange 322 so that the firstlocking tab 313B engages with one of the flats of the hex head of thebolt, and so that the second locking tab 313C engages with the free endof the first flange 322 when the bolt is inserted through the first andsecond flanges 322, 324. So assembled, the washer 313 cooperates withthe first flange 322 to preclude rotation of the bolt 312 with respectto the hanger 314.

FIGS. 8A-8C show yet another illustrative system 410 including a bolt412 and a hanger 414 according to the present disclosure. The system 410is in many or most respects similar to the system 110 and will bediscussed herein primarily in terms of its differences from system 110.Features of the system 410 having counterparts in the system 110 may bereferred to herein using like terms and may be identified by likereference characters, incremented by 300.

The bolt 412 differs from the bolt 112 primarily in that the head 416 ofthe bolt 412 is a conventional hex head. The bolt 412 otherwise issimilar to the bolt 112. As shown, the system 410 includes aconventional U-shaped hanger 414 having first and second flanges 422,424, although a hanger similar to the hanger 114 is contemplated for usein the system 410.

Unlike the first flange 122 of the system 110, the free (lower) end ofthe first flange 422 is turned outwardly (away from the second flange424) to define a locking tab 425 configured to engage with a flat of thehead 416 of the bolt 412 when the bolt is inserted through the first andsecond apertures 430, 432 defined by the first and second flanges. Soassembled, the locking tab 425 cooperates with the head 416 of the bolt412 to preclude rotation of the bolt with respect to the hanger 414.

FIGS. 9A-9C show yet a further illustrative system 510 including a bolt512 and a hanger 514 according to the present disclosure. The system 510is in many or most respects similar to the system 110 and will bediscussed herein primarily in terms of its differences from system 110.Features of the system 510 having counterparts in the system 110 may bereferred to herein using like terms and may be identified by likereference characters, incremented by 400.

The bolt 512 differs from the bolt 112 primarily in that the head 516 ofthe bolt 512 is a conventional hex head. The bolt 512 otherwise issimilar to the bolt 112. As shown, the system 510 includes aconventional U-shaped hanger 514 having first and second flanges 522,524, although a hanger similar to the hanger 114 is contemplated for usein the system 510.

Unlike the system 110, the system 510 also includes a washer 513 havinga generally planar base 513A and a lanced locking tab 513B extendingoutwardly from the base. The lanced locking tab 513B may be formed bylancing corresponding portions of the base 513A of the washer andpressing the portion of the base between the lanced portions out of theplane of the base. The washer 513 is disposed between the head 516 ofthe bolt 512 and the outer surface of the first flange 522 so that thelanced locking tab 513B engages with one of the flats of the head of thebolt when the bolt is inserted through the first and second flanges 522,524. The washer 513 may include serrations in its surface facing theouter surface of the first flange 522 to mitigate a tendency of thewasher to rotate with respect to the first flange. So assembled, thelanced locking tab 513B of the washer 513 cooperates with the head 516of the bolt 512 to preclude rotation of the bolt with respect to thehanger 514.

FIGS. 10A-10C show still another illustrative system 610 including abolt 612 and a hanger 614 according to the present disclosure. Thesystem 610 is in many or most respects similar to the system 110 andwill be discussed herein primarily in terms of its differences fromsystem 110. Features of the system 610 having counterparts in the system110 may be referred to herein using like terms and may be identified bylike reference characters, incremented by 500.

The bolt 612 differs from the bolt 112 primarily in that the head 616 ofthe bolt 612 is a conventional hex head. The bolt 612 otherwise issimilar to the bolt 112. As shown, the system 610 includes aconventional U-shaped hanger 614 having first and second flanges 622,624, although a hanger similar to the hanger 114 is contemplated for usein the system 610.

Unlike the first flange 122 of the system 110, the free (lower) end ofthe first flange 422 includes an integral lanced locking tab 627extending outwardly from the first flange 622. (The lanced locking tab627 is similar to the lanced locking tab 513B extending outwardly fromthe base 513 of the washer 513 of the system 510, and the lanced lockingtab 627 may be formed in a similar manner as the lanced locking tab513B.) The lanced locking tab 627 is configured to engage with a flat ofthe head 616 of the bolt 612 when the bolt is inserted through the firstand second flanges 622, 624. So assembled, the lanced locking tab 627cooperates with the head 616 of the bolt 612 to preclude rotation of thebolt with respect to the hanger 614.

FIGS. 11A-11D are various views of an alternative spring hanger 114″that could be used in lieu of the spring hanger of any of the foregoingembodiments. The spring hanger 114″ is similar to the spring hanger 114but is tubular and, therefore, lacks a gap analogous to the gap 134 ofthe spring hanger 114. As such, the spring hanger 114″ includes a firstside 120″ analogous to the web 120 of the spring hanger 114, a secondside 122″ analogous to the first flange 122 of the spring hanger 114, athird side 124″ analogous to the second flange 124 of the spring hanger114, and a fourth side 125″ or return web in place of the first andsecond returns 126, 128 and intervening gap 134 of the spring hanger114. The second and third sides 122″, 124″ may define respectiveapertures 130″, 132″. The spring hanger 114″ may be laser cut orotherwise cut or formed from a section of rectangular tube.

FIGS. 11E-11H are various views of another alternative spring hanger 714that could be used in lieu of the spring hanger of any of the foregoingembodiments. The spring hanger 714 is similar to the spring hanger 114but the first and second flanges 722, 724 include a bevel or taperbeyond the midpoint M′ of the hanger. That is, the first and secondflanges 722, 724 taper from the midpoint M′ toward distal ends of thefirst and second flanges.

FIGS. 12A-12E are various view of an alternative bolt 1212 for use witha modified spring hanger 1214. The alternative bolt 1212 includes a head1216, a shank 1218, and a key portion 1217 intermediate the head and theshank. The head 1216 may have a circular and domed shape. The keyportion 1217 may have a square cross-section configured to be receivedin and engage with sidewalls of a complementary square aperture, as willbe discussed further below. The shank 1218 may be similar to the shank118 of the bolt 112. The modified spring hanger 1214 may be identical tothe spring hangers 114, 114″ except that one or both of the first andsecond apertures 1230, 1232 of the modified spring hanger 1214 have asquare cross-section whereas the first and second apertures 130, 132,130″, 132″ of the spring hangers 114, 114″ have a round cross-section.In use, the alternative bolt 1212 may be inserted through the apertures1230, 1232 of the modified spring hanger 1214 so that the key portion1217 of the bolt is received within a corresponding one of theapertures. With the alternative bolt 1212 so received within themodified spring hanger 1214, the key portion 1217 cooperates with thecorresponding aperture 1230, 1232 to inhibit rotation of the alternativebolt with the modified spring hanger 1214.

Material specifications, dimensions, and the like that may be shown inthe drawings are illustrative and not limiting.

While the invention has been described in connection with what ispresently considered to be the most practical and preferred embodiments,it is to be understood that the invention is not to be limited to thedisclosed embodiments, but on the contrary, is intended to cover variousmodifications and equivalent arrangements included within the spirit andscope of the appended claims.

The invention claimed is:
 1. An axle hanger comprising: a web; a first flange extending in a first direction perpendicular to the web; a second flange extending in the first direction perpendicular to the web, spaced from and parallel to the first flange; a first return extending from the first flange toward the second flange parallel to the web; and a second return extending from the second flange toward the first flange parallel to the web, wherein the web has a first length, the first and second flanges have a second length, and the first and second returns have a third length, and wherein the third length is less than half of the first length such that the first and second returns define a gap between them.
 2. An axle hanger according to claim 1, wherein the first flange comprises a first aperture, and wherein the second flange comprises a second aperture, the first and second apertures being coaxial.
 3. An axle hanger according to claim 1, wherein the second length is greater than the first length.
 4. An axle hanger according to claim 1, wherein the axle hanger is formed from a blank including bend lines or regions such that the web, the first and second flanges, and the first and second returns are integral.
 5. An axle hanger according to claim 1, wherein the first and second returns are coplanar.
 6. An axle hanger according to claim 1, wherein the first and second returns are connected or integral to define a return web.
 7. An axle hanger according to claim 1, wherein the web and the first and second returns are positioned above a midpoint of the axle hanger, and wherein the first and second flanges extend below the midpoint, the first and second flanges tapering from the midpoint toward distal ends of the first and second flanges.
 8. An axle hanger comprising: a web extending having a first depth; a first flange extending in a first direction perpendicular to the web; a second flange extending in the first direction perpendicular to the web, spaced from and parallel to the first flange, wherein the first and second flanges have a second depth larger than the first depth; a first return extending from the first flange toward the second flange parallel to the web; and a second return extending from the second flange toward the first flange parallel to the web.
 9. An axle hanger according to claim 8, wherein the first and second returns have a return depth matching the first depth.
 10. An axle hanger according to claim 9, wherein the first flange comprises a first aperture, and wherein the second flange comprises a second aperture, the first and second apertures being coaxial.
 11. An axle hanger according to claim 10, wherein the first and second apertures are positioned beyond the first depth.
 12. A method of assembling an axle hanger, the method comprising: (a) cutting or stamping a blank from a metal sheet or plate, the blank including a web portion, a first flange portion immediately adjacent the web portion along a first bend line or region, a second flange portion immediately adjacent the web portion along a second bend line or region spaced from and parallel to the first bend line or region, a first return portion immediately adjacent the first flange portion along a third bend line or region spaced from and parallel to the first bend line or region, and a second return portion immediately adjacent the second flange portion along a fourth bend line or region spaced from and parallel to the second bend line or region; (b) bending the first flange portion with respect to the web portion along the first bend line or region so that the first flange portion is perpendicular to the web portion; (c) bending the second flange portion with respect to the web portion along the second bend line or region so that the second flange portion is perpendicular to the web portion and spaced from and parallel to the first flange portion; (d) bending the first return portion with respect to the first flange portion along the third bend line or region so that the first return portion and the first flange portion are perpendicular to each other and so the that first return portion extends from the first flange portion toward the second flange portion; and (e) bending the second return portion with respect to the second flange portion along the fourth bend line or region so that the second return portion and the second flange portion are perpendicular to each other and so that the second return portion extends from the second flange portion toward the first flange portion and the first return portion.
 13. A method according to claim 12, further comprising forming a first aperture in the first flange portion, and forming a second aperture in the second flange portion.
 14. A method according to claim 12, wherein steps (d) and (e) are practiced such that the first return portion and the second return portion are coplanar. 